U.S. patent application number 16/986585 was filed with the patent office on 2021-02-18 for method and system for producing a sensor.
The applicant listed for this patent is SICK AG. Invention is credited to Andreas ESSLINGER, Daniel HOFSTATTER.
Application Number | 20210048804 16/986585 |
Document ID | / |
Family ID | 1000005047488 |
Filed Date | 2021-02-18 |
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United States Patent
Application |
20210048804 |
Kind Code |
A1 |
HOFSTATTER; Daniel ; et
al. |
February 18, 2021 |
Method and System for Producing a Sensor
Abstract
System and method for producing a sensor for a processing
machine/plant, wherein a digital twin sensor is provided that is
related to the sensor, wherein the digital twin sensor is stored in
a database (10), wherein the digital twin sensor forms a data model
of the sensor, wherein the data model comprises at least one data
building block with data for a sensor housing, for an electronic
system, for a control and evaluation unit, for a primary sensor
element and/or for mechanical components of the sensor, wherein the
digital twin sensor is loaded into a construction program for the
processing machine/plant, wherein the digital twin sensor is
configured in the construction program, wherein the digital twin
sensor is adapted to the processing machine/plant and the adapted
digital twin sensor is produced as a real adapted sensor.
Inventors: |
HOFSTATTER; Daniel;
(Waldkirch, DE) ; ESSLINGER; Andreas; (Waldkirch,
DE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SICK AG |
Waldkirch |
|
DE |
|
|
Family ID: |
1000005047488 |
Appl. No.: |
16/986585 |
Filed: |
August 6, 2020 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
G05B 2219/37494
20130101; G05B 19/4183 20130101; G05B 19/41865 20130101; G05B
19/4181 20130101 |
International
Class: |
G05B 19/418 20060101
G05B019/418 |
Foreign Application Data
Date |
Code |
Application Number |
Aug 13, 2019 |
DE |
102019121799.7 |
Claims
1. Method of producing a sensor for a processing machine/plant,
wherein a digital twin sensor is provided that is related to the
sensor, wherein the digital twin sensor is stored in a database,
wherein the digital twin sensor forms a data model of the sensor,
wherein the data model comprises at least one data building block
with data for a sensor housing, for an electronic system, for a
control and evaluation unit, for a primary sensor element and/or
for mechanical components of the sensor, wherein the digital twin
sensor is loaded into a construction program for the processing
machine/plant, wherein the digital twin sensor is configured in the
construction program, wherein the digital twin sensor is adapted to
the processing machine/plant, and the adapted digital twin sensor
is produced as a real adapted sensor.
2. The method in accordance with claim 1, wherein the data model
comprises construction data, functional data and/or design data of
the digital twin sensor.
3. The method in accordance with claim 1, wherein the data model
includes at least production specific pieces of information of the
digital twin sensor.
4. The method in accordance with claim 3, wherein the production
specific pieces of information comprise comparison values and/or
alignment values.
5. The method in accordance with claim 1, wherein data of the data
model are parameterization data and/or key figures of the digital
twin sensor.
6. The method in accordance with claim 1, wherein the sensor and
the digital twin sensor are connected to one another via an
interface, wherein data can be transferred at least from the sensor
to the digital twin sensor via the interface.
7. The method in accordance with claim 1, wherein the sensor and
the digital twin sensor each have an unambiguous identification
number which are linked to one another in order to unambiguously
associate the digital twin sensor with the sensor and/or the sensor
with the digital twin sensor.
8. The method in accordance with claim 1, wherein, during an
operating phase of the sensor, the data of the sensor is
continuously transmitted or transmitted at fixed intervals to the
digital twin sensor.
9. System for producing a sensor for a processing machine/plant,
wherein a digital twin sensor is provided that is related to the
sensor, wherein the digital twin sensor is stored in a database,
wherein the digital twin sensor forms a data model of the sensor,
wherein the data model comprises at least one data building block
with data for a sensor housing, for an electronic system, for a
control and evaluation unit, for a primary sensor element and/or
for mechanical components of the sensor, wherein the digital twin
sensor can be loaded into a construction program for the processing
machine/plant, wherein the digital twin sensor can be configured in
the construction program, wherein the digital twin sensor is
adapted to the processing machine/plant and the adapted digital
twin sensor is produced as a real adapted sensor.
Description
[0001] The present invention relates to a method for producing a
sensor in accordance with the preamble of claim 1 and to a system
for producing a sensor in accordance with the preamble of claim
8.
[0002] Sensors, such as for example, light barriers and light
scanners are used in large numbers today and for this reason are
developed and produced as standard devices for a broad field of
application.
[0003] Nevertheless, sensors in industrial plants have many
different tasks. Depending on the field of industry, the
requirements of these tasks for the sensors are very specific. It
is thus necessary to adapt the sensors to these specific
requirements.
[0004] Today setting possibilities are made accessible to the user
for the above mentioned adaptations. For example, a setting of a
working point or a setting of whether the sensor is light switching
or dark switching. As a rule, this takes place via buttons or
rotary knobs.
[0005] A different possibility is to parameterize the sensors via
bus systems, for example, IO link and a corresponding software. In
this way adaptations in the sensor software and the sensor firmware
can be carried out or, for example, ASIC parameter can be changed,
for example an adaptation of a switching hysteresis.
[0006] Besides the sensor parameterization frequently a cable
length has to be customized in order to be able to integrate the
sensors into a plant in an as space saving as possible manner.
[0007] Generally speaking the parameterization of the sensors takes
place in the plant at every individual device by a technician. On a
parameterization via bus systems, such as IO link, a computer is
required for the parameterization. This is very demanding in time
for a large number of utilized sensors.
[0008] In this connection if cable lengths have to be shortened
then this represents a waste of resources. The cable pieces by
means of which the sensor cables have to be shortened are discarded
and are never used for their intended purpose.
[0009] In order to be able to serve operate as many as possible
uses and/or applications with standard sensors, sensor
manufacturers frequently deliver the sensors with very long cables.
This increases the above mentioned problem. The alternative is to
have different cable lengths available as standard sensors;
however, this leads to high costs of storage.
[0010] An object of the invention exists therein to improve a
production of the sensor. In particular a parameterization and/or
an assembly of the sensor should take place on planing of the
plant.
[0011] This object is satisfied in accordance with claim 1 by a
method for producing a sensor for a processing machine/plant,
wherein a digital twin sensor is provided that is related to the
sensor, wherein the digital twin sensor is stored in a database,
wherein the digital twin sensor forms a data model of the sensor,
wherein the data model comprises at least one data building block
with data for a sensor housing, for an electronic system, for a
control and evaluation unit, for a primary sensor element and/or
for mechanical components of the sensor, wherein the digital twin
sensor is loaded into a construction program for the processing
machine/plant, wherein the digital twin sensor is configured in the
construction program, wherein the digital twin sensor is adapted to
the processing machine/plant and the adapted digital twin sensor is
produced as a real adapted sensor.
[0012] The object is further satisfied in accordance with claim 8
by a system for producing a sensor for a processing machine/plant,
wherein a digital twin sensor is provided that is related to the
sensor, wherein the digital twin sensor is stored in a database,
wherein the digital twin sensor forms a data model of the sensor,
wherein the data model comprises at least one data building block
with data for a sensor housing, for an electronic system, for a
control and evaluation unit, for a primary sensor element and/or
for mechanical components of the sensor, wherein the digital twin
sensor can be loaded into a construction program for the processing
machine/plant, wherein the digital twin sensor can be configured in
the construction program, wherein the digital twin sensor is
adapted to the processing machine/plant and the adapted digital
twin sensor is produced as a real adapted sensor.
[0013] The sensors to be produced are made available to a plant
designer in the form of the digital twin sensor in the construction
program. The construction program is a domain specific software,
such as for example, SolidWorks, Siemens NX Designer or similar
software.
[0014] The digital twin sensor enables all setting possibilities of
the sensor. Thereby the settings can be carried out already
virtually on the plant design.
[0015] In accordance with the invention configuration parameters
and certain hardware parameters can, for example be automatically
detected in the construction program and converted into a
production parameter in the digital twin.
[0016] For example, a distance along the optical axis of a digital
twin sensor to an object to be detected is recorded in the
construction program and converted in a digital twin into a
teaching value and/or a learning value. If the distance is, for
example, too large for the used digital twin sensor, a message
appears which recommends the use of a different sensor and, for
example offers a selection of the associated digital twin
sensor.
[0017] Furthermore, for example, a required cable length can be
automatically determined in the construction program, as soon as
the sensor is positioned and the position for the sensor
connections is known. The required cable length of the connection
cables is noted in the digital twin.
[0018] Having regard to the construction program this can also be a
program in which the digital twin sensor is adaptable, wherein the
construction program has an export function in order to make the
adapted digital twin sensor available to a different construction
program.
[0019] In accordance with the invention a fast installation of the
sensors in the plant is possible. The sensors are immediately ready
to work following the installation and already individually set up.
In exceptional cases the sensors by way of example still require a
fine adjustment. For example, a fine adjustment of the switching
point takes place, as the coarse switching point was already set on
the production of the sensor. If, for example, the digital twin
sensor is updated with the fine adjustment from the processing
machine/plant, then a parameterization is no longer required in
some circumstances on a sensor exchange.
[0020] In accordance with the invention an avoidance of waste and a
conservation of resources takes place. For example, if cable
lengths are made to measure, then the waste of cables does not
apply that would have to be shortened on assembly.
[0021] In an embodiment of the invention the data model comprises
construction data, functional data and/or design data of the
digital twin sensor. The construction data at least include the
used components and/or component groups, their dimensions and their
materials. The functional data at least include the function of the
used components and/or component groups, as well as data sheet
values for the specification of the component and/or the component
group. Design data, for example, include design rules for the
sensor assembly, such as, for example, optical rules.
[0022] In an embodiment of the invention the data model comprises
at least production specific pieces of information of the digital
twin sensor, namely comparison values and/or alignment values. The
comparison values and/or alignment values form a final setting of
the sensor for the specific sensor or, for example, a specific
purpose of use. In this way, for example, a sensitivity of the
sensor can be set or, for example, optical axes of the sensor can
be aligned.
[0023] In an embodiment of the invention the data are configuration
data, parameterization data and/or key figures of the digital twin
sensor. Parameterization data or configuration data are, for
example, a set range, a number of protective fields, a detection
field etc. of the sensor.
[0024] In an embodiment of the invention the sensor and the digital
twin sensor are connected one to another via an interface, wherein
data can be transmitted at least from the sensor to the digital
twin sensor via the interface.
[0025] Deviations between the digital twin sensor and the real
sensor can be determined in the real sensor or in the digital twin
sensor thereby that a comparison between the real sensor and the
digital twin sensor is carried out via the interface.
[0026] The interface can, for example be an ethernet interface
and/or an ethernet connection. However, also other kinds of
interfaces are possible. For example, the interface can be a bus
system. Optionally the interface is configured as a secure
interface, in particular an interface secure from errors. It can in
particular also be a secure bus system. The interface can be a
radio interface. The interface can be a remote interface, since the
sensor and the digital twin sensor are spatially separated from one
another. In this way the database with the digital twin sensor is
stored in a data processing center remote from the sensor.
[0027] In an embodiment of the invention the sensor and the digital
twin sensor each have an unambiguous identification number which
are linked with one another in order to unambiguously link the
digital twin sensor to the sensor and/or the sensor to the digital
twin sensor.
[0028] Following an adaptation of the digital twin sensor in the
construction program and/or in the plant design software, each
digital twin sensor obtains an unambiguous identification number in
the processing machine/plant of the user and/or of the customer and
an unambiguous identification number in the sensor production. With
this unambiguous identification number, the digital twin sensor is
sent to the sensor production as a production order.
[0029] During the sensor production the sensor is produced with the
corresponding cable lengths and parameterizations like for the
digital twin sensor. The newly produced sensor includes the same
identification number like its digital twin. In this way one can
ensure that the sensor has the same properties as its digital twin
sensor. Furthermore, it is ensured that the sensor is mounted at
the same position and in the same orientation in the plant as its
digital twin sensor.
[0030] A copy of the digital twin sensor associated with the
processing machine/plant is stored in an administration system.
Thus, a new real sensor can be produced in the replacement parts
business. By means of its unambiguous identification number it can
always be identified.
[0031] This copy of the digital twin sensor can be updated by the
customer if required, when a post alignment of the parameterization
takes place on taking into operation.
[0032] In an embodiment of the invention the data of the sensor are
continuously transmitted or transmitted at fixed intervals to the
digital twin sensor during an operating phase of the sensor.
[0033] Following a new installation of the sensor, the data can,
for example, be continuously transmitted between the sensor and the
digital twin sensor, as the sensor is subjected to environmental
conditions for the first time at this point in time and an
influencing of the sensor takes place with a high probability. In
this way the digital twin sensor is adapted to the real sensor.
[0034] In the course of operation and depending on the sensor
and/or the place of use, a transfer can take place at fixed
intervals with different spacings of, e.g. seconds, minutes, hours,
days, weeks, months or years.
[0035] The more dramatic and/or frequent the changes of
environmental conditions is, the more frequent a cyclic transfer of
data can take place.
[0036] The sensors can be light barriers, light scanners, light
curtains, light grids, cameras, 3D cameras, barcode readers, laser
scanners, inductive sensors, magnetic sensors, capacitive sensors
or the like.
[0037] The invention will be described in the following also with
regard to further advantages and features with reference to the
submitted drawings by means of embodiments. The Figures in the
drawing show:
[0038] FIG. 1 and FIG. 2 a respective system and method in
accordance with the invention for producing a sensor.
[0039] In the following Figures identical parts are provided with
identical reference numerals.
[0040] FIG. 1 shows a system 1 and/or a method for producing a
sensor 2 for a processing machine/plant 8, wherein a digital twin
sensor 9 is provided that is related to the sensor 2, wherein the
digital twin sensor 9 is stored in a database 10, wherein the
digital twin sensor 9 forms a data model 11 of the sensor 2,
wherein the data model 11 comprises at least one data building
block 17 with data for a sensor housing 3, for an electronic system
4, for a control and evaluation unit 5, for a primary sensor
element 6 and/or for mechanical components 7 of the sensor 2,
wherein the digital twin sensor 9 can be loaded into a construction
program 13 for the processing machine/plant 8, wherein the digital
twin sensor 9 can be configured in the construction program 13,
wherein the digital twin sensor 9 is adapted to the processing
machine/plant 8 and the adapted digital twin sensor 9 is produced
as a real adapted sensor 2.
[0041] The sensors 2 to be produced are made available to a plant
designer in the form of the digital twin sensor 9 in the
construction program 13. The construction program 13 is a domain
specific software, such as, for example, SolidWorks, Siemens NX
Designer or similar software. A digital model 14 of the processing
machine/plant is present in the construction program 13.
Furthermore, also a digital model 16 of objects 15 is present.
[0042] The digital twin sensor 9 enables all setting possibilities
of the sensor 2.
[0043] In accordance with FIG. 1 configuration parameters and
certain hardware parameters can, for example, be automatically
detected in the construction program 13 and converted into a
production parameter in the digital twin sensor 9.
[0044] By way of example, a distance 18 along the optical axis of a
digital twin sensor 9 to a digital model 16 of an object 15 to be
detected is detected in the construction program 13 and is
converted to a teaching value and/or a learning value in the
digital twin sensor 9. For example, if the distance 18 is too large
for the used digital twin sensor 9, then a notification appears
which recommends the use of a different sensor and, for example,
offers a selection of the associated digital twin sensor 9.
[0045] Furthermore, for example, a required cable length can be
automatically determined in the construction program 13, as soon as
the digital twin sensor 9 is positioned and the position for the
sensor connections is known. The required cable length of the
connection cable is noted in the digital twin sensor 9.
[0046] The construction program 13 can also be a program in which
the digital twin sensor 9 can be adapted, wherein the construction
program 13 has an export function in order to make available the
adapted digital twin sensor 9 to a different construction program
13.
[0047] In accordance with FIG. 1 the data model 11 has construction
data, functional data and/or design data of the digital twin sensor
9.
[0048] In accordance with FIG. 1 the data model 11 includes at
least production specific pieces of information of the digital twin
sensor 9, namely comparison values and/or alignment values. By way
of example, a sensitivity of the digital twin sensor 9 and/or of
the sensor 2 can thus be set or, for example, optical axes of the
digital twin sensor 9 and/or of the sensor 2 can be adjusted.
[0049] In accordance with FIG. 1, the data are configuration data,
parameterization data and/or key figures of the digital twin sensor
9. Parameterization data or configuration data are, for example, a
set range, a number of protective fields, a detection field etc. of
the sensor 2 and/or of the digital twin sensor 9.
[0050] In accordance with FIG. 2, the sensor 2 and the digital twin
sensor 9 are connected one to another via an interface 12, wherein
data can be transmitted at least from the sensor 2 to the digital
twin sensor 9.
[0051] Deviations between the digital twin sensor 9 and the real
sensor 2 can be determined in the real sensor 2 or in the digital
twin sensor 9 thereby that a comparison between the real sensor 2
and the digital twin sensor 9 is carried out via the interface
12.
[0052] In accordance with a non-illustrated embodiment the sensor
and the digital twin sensor each have an unambiguous identification
number which are linked with one another in order to unambiguously
associate the digital twin sensor with the sensor and/or the sensor
with the digital twin sensor.
[0053] Following the adaptation of the digital twin sensor in the
construction program and/or in the plant design software each
digital twin sensor receives an unambiguous identification number
in the processing machine/plant of the user and/or customer and an
unambiguous identification number in the sensor production. With
this unambiguous identification number, the digital twin sensor is
sent to the sensor production as a production order.
[0054] In the sensor production the sensor is produced with the
corresponding cable lengths and parameterizations, as for the
digital twin. The newly produced sensor includes the identical
identification number as its digital twin.
[0055] In accordance with FIG. 2 the data of the sensor 2 are
continuously transmitted or transmitted at fixed intervals to the
digital twin sensor 9 during an operating phase of the sensor
2.
[0056] Following a new installation of the sensor 2, the data can,
for example, be continuously transmitted between the sensor 2 and
the digital twin sensor 9, as the sensor 2 is subjected to
environmental conditions for the first time at this point in time
and an influencing of the sensor 2 takes place with a high
probability. In this way the digital twin sensor 9 is adapted to
the real sensor 2.
[0057] The sensors 2 in accordance with FIGS. 1 to 2 can be light
barriers, light scanners, light curtains, light grids, cameras, 3D
cameras, barcode readers, laser scanners, inductive sensors,
magnetic sensors, capacitive sensors or the like.
REFERENCE NUMERALS
[0058] 1 system [0059] 2 sensor [0060] 3 sensor housing [0061] 4
electronic system [0062] 5 control and evaluation unit [0063] 6
primary sensor element [0064] 7 mechanical components [0065] 8
processing machine/plant [0066] 9 digital twin sensor [0067] 10
database [0068] 11 data model [0069] 12 interface [0070] 13
construction program [0071] 14 digital model of the processing
machine/plant [0072] 15 object [0073] 16 digital model of the
object [0074] 17 data building blocks [0075] 18 distance
* * * * *